TECHNICAL SERVICES GROUP

SPECIFICATION FOR GENERAL WELDING

CAIRN-TSG-L-SP-0009

CAIRN ENGINEERING STANDARD

B1 24/09/2012 Issued for Implementation N Rao Vijay B AA

Revision Date Description Originator Checker Approver

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SPECFICATION FOR GENERAL WELDING
CAIRN-TSG-L-SP-0009 B1
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REVISION RECORD

Revision Philosophy
All revisions for review will be issued at A1, with subsequent A2, A3, etc as required.
All revisions approved for issue or implementation will be issued at B1, with subsequent B2, B3, etc as
required.
All revisions approved for issue or design and construction will be issued at C1, with subsequent C2, C3, etc
as required.
Narrative sections revised from previous pprove issues are to be noted in the table below and/or highlighted
using the appropriate revision status thus: | A2
Previous revision highlighting to be removed at subsequent issues.
Drawings/diagrams revised from previous approved issues are highlighted by 'clouding' the affected areas and
by the use of a triangle containing the revision status.

Revision History

Revision Date of Reason for change

No. issue

A1 Aug 2012 Issued for review

B1 24/09/2012 Issued for Implementation

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SPECFICATION FOR GENERAL WELDING
CAIRN-TSG-L-SP-0009 B1
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TABLE OF CONTENTS
1.0 SCOPE 4
2.0 DEFINITION AND ABBREVIATIONS 4
3.0 REFERENCES 4
4.0 WELDING PROCEDURES 4
5.0 WELDING PROCESS 5
6.0 WELDING ELECTRODES AND CONSUMABLES 6
7.0 GENERAL WELDING REQUIREMENTS 6
8.0 NONDESTRUCTIVE EXAMINATION (NDE), TESTING AND INSPECTION 10
9.0 CLAD RESTORATION, WELD METAL OVERLAY AND DISSIMILAR METAL WELDING 12
10.0 ADDITIONAL WELDING REQUIREMENTS FOR STRUCTURAL STEELFABRICATIONS 14
11.0 ADDITIONAL WELDING REQUIREMENTS FOR PRESSURE VESSELS & HEAT EXCHANGERS 15
12.0 ADDITIONAL WELDING REQUIREMENTS FOR ATMOSPHERIC & LOW PRESSURE STORAGE
TANKS 17
13.0 ADDITIONAL WELDING REQUIREMENTS FOR BOILERS, HEATS & FURNACES 17
14.0 ADDITIONAL WELDING REQUIREMENTS FOR AUXILIARY SUPPORT COMPONENTS 18
15.0 ADDITIONAL WELDING REQUIREMENTS FOR FABRICATED PIPING & PIPING COMPONENTS 19
16.0 WELDING REPAIRS 21

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SPECFICATION FOR GENERAL WELDING
CAIRN-TSG-L-SP-0009 B1
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1.0 SCOPE
This specification covers the minimum requirements for the welding of shop and field fabrication and the
weld inspection of the following equipment:
x Pressure containing equipment and piping whether code stamped or not, including but not limited to
rotating equipment, boilers, pressure vessels, heat exchangers, air coolers, shop and field fabricated
piping, fired heaters tubes, storage tanks, and their attachments.
x Equipment or piping containing toxic or corrosive materials when specified in the job specifications.
x Structural steel fabrications
x Other fabrications where specified
This specification modifies the requirements of applicable ASME, ANSI, API and AWS codes and
standards in effect at the time. It also modifies API and AWS standards when specified. The applicable
edition, revision, addenda, etc., shall be specified in the equipment design, drawing data sheet, job
specification and/or purchase order. If an applicable code or standard is more stringent than this
specification, that standard shall govern.
In addition to this specification, boilers and piping connected with steam system shall be designed and
fabricated per the requirements of the Indian Boiler Regulations (IBR). Vendor shall obtain all necessary
approvals from the regulatory authority for the steam system equipment design and fabrication.
2.0 DEFINITIONS & ABBREVIATIONS
Company
The Company means Cairn Energy India Limited, and its subsidiaries or authorized representatives.
Vendor / Supplier
The Vendor or Supplier is the party that manufactures and supplies equipment and service to perform
the duties specified by the Company.
3.0 REFERENCES
Unless otherwise stated, the following Codes, Standards and Project Documents shall be of the latest
issue (including revisions, addenda and supplements) and are considered part of this specification.
ASME B31.3 - Chemical Plant and Petroleum Refinery Piping
ASME B31.1 - Power Piping
ASME Section II, Part C - Welding Rods, Electrodes and Filler Materials
ASME Section V - Non-Destructive Examination
ASME Section IX - Welding and Brazing Qualifications
NACE RP-0472-95 - Methods and Controls to Prevent In-Service Cracking of Carbon
Steel Welds in P-1 Materials in Corrosive Petroleum Refinery
Environments
IBR - Indian Boiler Regulations

4.0 WELDING PROCEDURES

Welding Procedure Specifications and Procedure Qualification Test records for vendor welding covered
by this specification shall be submitted to Company for review and acceptance prior to start of any
welding. No welding shall commence until welding procedure specifications and qualification records
have been accepted.
Welding performed by sub-vendors is also required to have welding procedures submitted for review and
acceptance by purchaser the same as above. Vendors are urged to review their sub-vendor’s welding
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SPECFICATION FOR GENERAL WELDING
CAIRN-TSG-L-SP-0009 B1
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procedures for conformance to this specification prior to submitting to Company or its designee for
acceptance.
The information contained in Welding Procedure Specifications and Procedure Qualification Test
Records shall include, but not be limited to the information contained in ASME Code, Section IX.
Welding Procedure Specifications shall conform to ASME Section IX form QW-482 or equivalent.
Procedure Qualification Records shall conform to ASME Section IX form QW-483 or equivalent.
Structural steel welding procedures may conform to AWS Prequalified or AWS recommended formats.
This specification includes additional requirements or restrictions that may not be listed in the vendor's
submitted welding procedure. They are to be listed, when required by this specification, either in the
welding procedure, special addenda to the welding procedure, or on the Weld Map.
Welding Performance Qualification test records shall be made available to Company personnel for
review upon request. Welding Performance tests shall be in accordance with ASME Section IX, under
conditions of restraint and accessibility as demanding as those to be experienced in production by the
welder. Welding Performance test records shall conform to ASME Section IX form QW-484 or
equivalent. Structural steel welding performance qualification records may comply with AWS
recommended format.
When impact testing is required by the code or job specifications, impact test results for weld and heat
affected zone shall be reported with the welding procedure qualifications.
When maximum Brinell hardnesses are required by code, the job specifications, or this specification,
they shall be reported with the Welding Procedure Qualification Record and they shall not exceed the
maximum specified.
Welders and welding operators shall be qualified within the previous 180 days and in accordance with
the requirements of AWS D1.1, Section 4 except qualification for T, K and Y joints shall be qualified in
the 6-GR position.
Welders to be used shall be qualified for each welding procedure they will use in the position they will
use it. Vendor shall make available to the Company’s inspector a copy of each welder’s qualification
certificate, with name and stencil I.D. Welds made with uncertified welders shall be removed and
replaced by a certified welder at the Vendor’s expense. The Vendor shall bear all costs for qualifying
welders.
Vendor’s QA/QC Supervisor shall maintain all Welder Qualification Records and make available to
Company Representative when requested.
5.0 WELDING PROCESS
5.1 The following welding processes are approved for use.
5.2 Shield Metal Arc welding (SMAW)
Gas Tungsten Arc Welding (GTAW)
Submerged Arc welding (SAW)
Gas Metal Arc Welding (GMAW) Spray/Pulse Transfer only
Use of any alternate arc fusion welding processes is subjected to COMPNAY approval. VENDOR should
clearly identify the proposed welding process, welding experience, level of automation and metal transfer
mode.
5.3 The root pass of welds in all materials except galvanized iron shall be performed using GTAW process
for the following application.
All pipes of nominal diameter less or equal to 2”.
All single sided alloy, stainless steel and nickel alloy piping, for large diameter piping where there is
access inside the pipe to allow double sided welding GTAW root may be omitted.

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SPECFICATION FOR GENERAL WELDING
CAIRN-TSG-L-SP-0009 B1
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6.0 WELDING ELECTRODES AND CONSUMABLES

6.1 Filler materials and fluxes shall be as specified in ASME, Section II, part C. Filler materials and fluxes
other than those specified in the above code and which meet other requirements of this specification
shall not be assumed to be acceptable by vendor during bid preparation.
6.2 All welding electrodes and consumables shall be subjected to COMPANY Approval as part of WPS
approval.
6.3 All welding consumables shall be supplied along with original manufacturer test certificates.
6.4 The electrode/filler wire chemistry shall meet the requirements of the base material, and shall be
selected such that the deposited weld metal exhibits mechanical properties equal or excess of the base
metal.
6.5 For any dissimilar metal weld applications welding consumables and procedure shall be subjected to
COMPANY approval.
6.6 All welding electrode/consumables shall as a minimum, be stored and used in accordance with the
manufacturer’s recommendations. The VENDOR shall produce a welding consumable handling and
storage procedure which is subjected to COMPANY approval.
6.7 Carbon, Low alloy, Stainless steel and special electrode shall be stored separately.
6.8 For submerged arc welding alloying is not permitted via the flux.
7.0 GENERAL WELDING REQUIREMENTS
7.1 Welding Equipment
Vendor and their sub-vendors shall maintain all equipment in good working conditions with valid
calibration certificates.
7.2 Weld joint Design and preparation
Weld joint design shall confirm to the allocable design code, project specification or approved drawings.
Weld joint shall be prepared by machining, grinding or thermal cutting.
Alloy materials shall be SAW or PLASMA cutting
When thermal cutting is employed all slag and heat affected areas shall be dressed by mechanical
means.
Weld joint tolerances for root and alignment shall meet the requirements of applicable code,
specification, approved drawing and the sketch details included in the approved WPS.
When poor fitted joints occur with excessive joint gap or offset or any other discrepancies, a repair
procedure shall be prepared and submitted for COMPANY review and approval. Welding shall not
perform on poorly fitted joints without CONPNAY’s concurrence.
Grinding and cleaning of austenitic stainless steel or higher nickel and nonferrous alloy shall be done
only with tools that have not been previously used on nonferrous materials, copper alloys, aluminum or
zinc coatings (paint or galvanized).
Care must be taken during fabrication, transportation and erection to prevent carbon contamination of
austenitic stainless steel or
7.3 Technique
Vertical down welding shall not be used without company approval.
All welds shall be cleaned of foreign materials (slag etc.) down to clean metal both on completion of
each pass and when the weld is finished.
Single pass welding procedures are not acceptable.

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SPECFICATION FOR GENERAL WELDING
CAIRN-TSG-L-SP-0009 B1
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All piping butt-weld shall be full penetration welds.

A minimum of two passes shall be used on socket and seal welding.
Weld penning shall not be used with COMPNAY approval.
All tack welds shall be made by the qualified welders. The required preheat temperature shall be
maintained prior to any tack welding. Tack welds which are to be incorporated into the final weld shall be
thoroughly cleaned, prepared at each end and inspected for cracks any cracked tacks shall be removed
before welding starts.
7.4 Preheating and inter pass temperature
Preheat shall be in accordance with that specified by the applicable Design code. In no instance shall
that preheat be less than 10°C. Minimum preheat shall be specified in the WPS/PQR.
The minimum preheat temperature shall be maintained throughout the welding cycle.
Minimum preheat requirements shall apply to all types of welding, including tack welds, temperature
attachments, repair welds, seal welds of threaded joints and thermal cutting.
If a welding joint is wet or has surface moisture or condensation it shall be dried by heating.
Maximum inter pass temperature shall be stated in approved WPS/PQR.
Maximum inter pass temperature for austenitic stainless steel shall not exceed 175°C. This includes
dissimilar welds between austenitic stainless steel and carbon steel.
Unless specified otherwise maximum inter pass temperature for P-1 materials shall be 250°C
Approved temperature indicating crayons, thermocouples or contact pyrometers shall be used to
measure preheat and inter pass temperatures.
7.5 Weld Repairs
For the repair of the weld either the original WPS or one originally submitted as a designated repair WPS
shall be used.
Repair plans that use welding for repair of welds or base metals when allowed shall be submitted for
COMPNAY approval prior to use and shall include the following.
x The method of defining the type and extent of the defect.
x Methods used for removing the defect and testing conducted to ensure that the defect has been
removed.
x Welding procedure and NDE procedures used to inspect the completed repair.
All repaired welds shall as a minimum be inspected using the original testing method. Additional test
methods may also be required if deemed necessary by the COMPANY.
7.6 Weld metal Quality
All welding shall meet the requirements of the applicable design code.
Arc strikes outside the weld groove shall be removed by disc grinder and minimum design wall thickness
shall be maintained.
Welds containing cracks and their cause shall be reported to COMPANY. If cracking is found during
NDE, examination levels shall be increased at COMPANY’s discretion until the cause of the cracking
has been identified, steps taken to prevent its reoccurrence. Weld containing cracks may be repaired
welding unless stated otherwise in writing by the COMPANY.
Acceptance standards for welds shall be in accordance with the applicable design code and
specification.
7.7 Postweld Heat Treatment

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CAIRN-TSG-L-SP-0009 B1
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Postweld heat treatment (PWHT) shall be performed in accordance with the requirements of the ASME
code as applicable. The applicable code for PWHT shall be referenced on the “Weld Map (Appendix 1).
The maximum and minimum holding temperatures shall be included in the WPS.
Direct impingement by torch or burner is not acceptable.
Threads and gasket surfaces shall be protected from oxidation during PWHT.
PWHT of P-8 materials, nonferrous alloy materials, and dissimilar materials require specific Company
approval.
When local PWHT is performed on materials 50 MM (2”) and greater in thickness, the minimum required
temperature must be monitored and verified on the unheated side of the material.
All PWHT methods require complete temperature control and chart recording capabilities. The complete
cycle of heating, holding and cooling temperatures and times must be included on the chart.
Acceptable methods of PWHT are:
x Furnace method.
x Internal fuel firing method.
x Local resistance method.
x Local induction method.
Other methods of PWHT require specific Company approval.
PWHT procedures for internal fuel firing and specialized local resistance heating methods on equipment,
other than piping, shall be submitted to Company for approval. The procedures shall include as a
minimum the following information and details:
x Equipment requirements for heating and recording controls. Include all spare equipment for
contingency purposes.
x Insulation requirements both internally and externally. Include type, thickness, and banding
requirements.
x Sketch or drawing showing equipment support, burner locations, thermocouple layout and insulating
boundaries.
x Thermal growth considerations, including calculations.
x Fuel supply or electrical power requirements.
x Personnel requirements.
x PWHT time/temperature requirements.
Maximum PWHT shall not exceed the following temperatures for boilers, pressure vessels, heat
exchangers, fired heaters, storage tanks and their attachments, unless specific Company approval is
obtained:

Min. Time Brinell Hardness

P-No. Base Material Max PWHT Temp.
Hours Max.

1 Carbon Steel 650ºC (1200ºF) 1 200

3 Carbon ½ Mo 705ºC (1300ºF) 1 225

4 1 ¼ Cr - ½ Mo 745ºC (1375ºF) 2 225

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CAIRN-TSG-L-SP-0009 B1
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5A 2 ¼ Cr - 1 Mo 745ºC (1375ºF) 2 241

5B 5 Cr - ½ Mo 745ºC (1375ºF) 2 241

5B 9 Cr - 1 Mo 745ºC (1375ºF) 2 241

6 13 Cr 760ºC (1400ºF) 2 241

Maximum PWHT shall not exceed the following temperatures for piping:

Temp. Hrs./In. Min. Max.

Metal Temp. Brinell
Base Rise ºC/Hr. Nom. Time Temp.
P-No. Hardness
Material ºC (ºF) Wall Hrs. Fall, ºC/Hr
(ºF/Hr.) Max.
(to 315ºC)

Carbon 595-650
1 222 (400) 1 1 110 200
Steel (1100-1200)

Carbon ½ 595-720
3 222 (400) 1 1 110 225
Mo (1100-1325)

705-745
1 ¼ Cr - ½
4 222 (400) 1 2 110 225
Mo
(1300-1375)

705-760
2 ¼ Cr- 1
5A 222 (400) 1 2 110 241
Mo
(1300-1400)

705-760
5 Cr -½
5B 222 (400) 1 2 110 241
Mo
(1300-1400)

705-760
5B 9 Cr- 1 Mo 222 (400) 1 2 60 241
(1300-1400)

730-785
6 13 Cr 222 (400) 1 2 60 241
(1350-1450)

PWHT may be required for carbon steel materials because of specific service conditions, even when not
required by the applicable code or standard. PWHT requirements for these services will be included in
the project specifications. When not specifically addressed in the project specifications, the following
service conditions will require PWHT as noted:
x Welds in piping and equipment in amine service for all operational temperatures shall be PWHT’d.

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CAIRN-TSG-L-SP-0009 B1
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x Welds in piping and equipment in caustic service shall be PWHT’d when the operating temperature
is above 60ºC (140ºF) and the caustic concentration is <30%; operating temperature is above 43ºC
(110ºF) and the caustic concentration is >30%; or, at any operating temperature when the
equipment or piping is heat traced or subject to steam out conditions.
x Welds in piping and equipment in anhydrous ammonia service shall be PWHT’d, if the water content
is 0.2% or less by weight.
x Welds in equipment in wet H2S service (minimum 50 wppm H2S in a separate water phase) shall be
PWHT’d. Welds in piping in wet H2S service shall be PWHT’d when the thickness at the weld joint >
19 mm (3/4”), or at any time that the as-welded hardness of the weld exceeds 200 BHN.
x Welds in piping and equipment in sour service (H2S in the presence of hydrogen at temperatures
above 232ºC (450ºF) and at partial pressure greater than 0.35 kPa (0.05 psi) and total pressure
greater than 450 kPa (65 psia) shall be PWHT’d.
x Welds in equipment in hydrogen service (any process stream with hydrogen partial pressure greater
than 345 kPa (50 psia) or when a client or licenser specifies a stream to be in hydrogen service)
shall be PWHT’d if the operating conditions are within 55ºC (100ºF) of the Nelson Curve for the
material (API Publication 941).
8.0 NONDESTRUCTIVE EXAMINATION (NDE), TESTING AND INSPECTION
NDE procedures and technician certifications shall be available for review by the Company inspector
during the course of fabrication. NDE shall be performed and evaluated in accordance with the
applicable ASME code or API standard. NDE in excess of code requirements shall be as specified in
theproject specifications or this specification. The more stringent specification or code requirement shall
govern.
As a minimum, or when NDE is not specified, all welds shall be visually examined in accordance with the
applicable code or standard.
When PWHT is required, all NDE shall be performed after PWHT for final acceptance.
When impact testing is required by ASME Code or project specifications, impact test temperature and
results for weld and heat affected zone (HAZ) shall be reported on the PQR.
The Company inspector shall be authorized to reject work or materials that fail to meet the acceptance
level of the project specifications or applicable code or standards.
Plate material 50 mm (2”) and greater in thickness, when used for pressure retaining components, shall
be ultrasonically examined by the straight-beam method in accordance with ASTM A578. The
acceptance standard shall be Level B.
Plate edges, including weld bevel preparation, shall be examined for laminar-type discontinuities on all
P-1 materials > 31.75 mm (1-1/4”), P-3 materials > 19 mm (3/4”), and all P-4 and P-5 materials
regardless of thickness. Examination shall be by magnetic particle or liquid penetrant methods. All
relevant indications shall be removed by gouging or grinding, and repaired by welding using approved
welding procedure specifications. Relevant indications shall be as defined in ASTM A-20 section 9.3
and Table A1.14.
Plate materials used in the manufacture of 2-piece formed heads shall have the seam weld
radiographically examined 100% prior to forming.
The backside of double-sided groove welds shall be prepared by chipping, grinding or gouging to clean
sound metal. This area, and all finished weld surfaces, shall be examined by the magnetic particle
method for P-1 materials >31.75 mm (1-1/4”), P-3 materials >19 mm (3/4”), P-4 materials >16 mm (5/8”),
and all P-5, P-6, and P-7 materials regardless of thickness. (Note: The backside of double-sided groove
welds in P-4, P-5, and P-6 materials need not be examined unless there is an interruption of the preheat
maintenance).

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CAIRN-TSG-L-SP-0009 B1
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The backside of double-sided groove welds and all finished weld surfaces in all non-magnetic materials,
either solid alloy or alloy clad, shall be liquid penetrant examined.
Hardness Testing:

Hardness testing shall be performed when PWHT is specified, or when required by applicable codes,
standards, project specifications or purchase documents. Hardness testing shall be performed using a
portable hardness tester. Each indentation shall be made to include part of the weld and part of the heat
affected zone (HAZ) whenever practical. Hardness testing shall be performed by the Brinell Hardness
Test method, unless specific approval is given by Company to deviate from this test method. Whenever
possible, production hardness readings shall be taken on the side of the weldment which will be exposed
to the process environment.
When hardness testing is required on ASME Section VIII, Division 1 or 2 pressure vessels, shell & tube
exchangers and air cooled exchangers, the tests shall be taken as follows:
x One test for each longitudinal weld seam per shell course section, on the I.D. where practical.
x One test for each 50 lineal feet of circumferential weld seam, on the I.D. where practical.
x One test for longitudinal and end plate weld seams on box headers for air-cooled exchangers.
x One test for each DN100 (4”) diameter nozzle and above, unless more stringent requirements of an
API standard apply.
x As a minimum, one test shall be taken on pressure retaining welds for each welding process
employed and one test for each welder or welding operator used.
x When PWHT is required, hardness tests shall be taken after PWHT.
Hardness tests on piping, not covered by ASME Code, shall be as stated in the project specifications.
Hardness tests on equipment other than pressure vessels, heat exchangers, and piping, shall be as
stated in the applicable code, standard or project specifications.
Results of hardness tests shall be documented by the vendor and available for review by the Company
inspector. The Company inspector shall be consulted on the choice of locations for the tests.
Hardness test results shall be reported by the vendor with the PQR when submitting welding procedures
to Company for review and acceptance for the following:
x When hardness tests are required by applicable codes, standards or project specifications.
x When equipment or piping is PWHT’d.
x When automatic or machine type SAW process, or FCAW process is to be used for welding P-1
through P-6 materials.
Hardness for carbon steel shall not exceed 200 BHN. Hardnesses for low alloy materials shall be in
accordance with applicable codes and standards or as stated in this specification.
When NACE service is specified for carbon and low alloy steels in wet H2S service (NACE MR-
0175),welding procedures shall be qualified with hardness surveys performed in accordance with the
applicable Figures 2, 3, 4 or 5 found in NACE MR-0175. Acceptance criteria shall be per NACE MR-
0175, Table A.1.
When NACE RP-0472 is specified, welding procedure qualification (PQR) shall contain the results of a
cross-sectional Vickers Hv10 hardness survey using a maximum test load of 10 kg. Hardness survey
shall be performed in accordance with Figure 2 of NACE RP 0472. Hardness results shall not exceed
248 HV in the heat affected zone (HAZ) and weld deposit. The average weld deposit hardness shall not
exceed 210 HV. Production hardness testing shall be performed 100% on all welds, using the
BrinellHardness test methods. Production hardness results shall not exceed 200 HB.

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For both NACE MR-0175 & RP-0472 applications, the following additional welding procedure variables
shall be considered as essential:
x The wire brand name and type used for production welding shall be the same as used in procedure
qualification.
x The wire size used in production shall be the same as used in procedure qualification
x Heat input used during welding shall not vary by more than +25% and -10% from that used in
procedure qualification. Heat input shall be calculated according to the methods defined in ASME
Section IX and shown on the procedure qualification record (PQR). The welding procedure
specification (WPS) shall state the maximum allowable heat input within the tolerances specified
above.
x Preheat and Interpass temperatures used during production welding shall be greater than or equal to
that used in procedure qualification.
x For welds in pressure containing components, the diffusible hydrogen limit for filler metals shall be
measured in accordance with AWS A4.3. Limits of diffusible hydrogen shall be as follows:

Specified Minimum Tensile Strength Maximum Diffusible Hydrogen Designation (Per

for the Electrode (Per AWS/SFA 5.20) AWS/SFA 5.20)

”70 ksi H8

>70 ksi H4

x Shielding gas shall be checked to confirm a dew point of -40°F or lower. This may be accomplished
by obtaining written certification of shielding gas or by actual dew point measurement.
x If preheat is not used in procedure qualification, the maximum base metal thickness of production
weldments shall not exceed the thickness of the procedure qualification (PQR) test specimen.
9.0 CLAD RESTORATION, WELD METAL OVERLAY & DISSIMILAR METAL WELDING
Corrosion-Resistant Weld Metal Overlay, Hard-Facing Weld Metal Overlay, Joining of Composite (Clad
Metals), and Applied Linings:
Welding procedures shall be qualified to ASME Section IX, Paragraph(s), QW-214, QW-216, QW-217,
and QW-218 as applicable, unless more stringent requirements of this specification apply.
Corrosion-resistant weld metal overlay and clad restoration welding shall control dilution as evidence by
a chemical analysis for the PQR. The depth of the chemical analysis shall be taken approximately 2.4
mm (3/32”) below the required overlay thickness unless specified otherwise. The chemical analysis shall
indicate that the minimum chemical requirements meet the minimum specified for the weld metal or base
metal as follows:
x For 300 Series austenitic stainless steels and nickel-based alloys - The chemical composition of the
analysis shall be within the minimum requirements of the applicable SFA designation and AWS
Classification of the filler materials.
x For 400 Series ferritic or martensitic stainless steels - The chemical composition of the analysis shall
be within the minimum requirements of the applicable SFA designation and AWS Classification of
the filler materials, unless austenitic stainless steel or nickel-based alloy filler materials are used. In
these instances, the chemical composition of the analysis shall be within the minimum requirements
for chromium content of the applicable base material specification.
Corrosion-resistant weld metal overlay and clad restoration welding deposits shall be a minimum of two
passes, unless otherwise authorized by Company.

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The following arc-welding processes may be used for corrosion-resistant weld metal and hard-facing
overlay, clad restoration welding and welding of applied linings:
x Shielded Metal Arc Welding (SMAW) - Manual.
x Gas Tungsten-Arc Welding (GTAW) - Manual, machine or automatic, cold or hot wire.
x Submerged Arc Welding (SAW) - Automatic or machine, wire or strip electrode, single, tandem or
multi-head.
x Gas Metal Arc Welding (GMAW) - Semi-automatic, machine or automatic spray, globular, or pulsed
transfer modes only. Limited to three (3) deposit passes only.
x Flux Cored Arc Welding (FCAW) - Semi-automatic, machine or automatic spray transfer mode only.
Auxiliary shielding gas only, unless otherwise authorized by Company.
x Electroslag Welding (ESW) - Resistance Electroslag Surfacing (RES) process.
x Plasma-Arc Welding (PAW) - Plasma-arc hot-wire welding, gas-metal plasma-arc welding or
plasma-MIG welding.
The following preparations shall be used on all alloy clad materials prior to clad restoration welding:
x Cladding shall be stripped back to a minimum of 6.35 mm (¼”) from the edge of the backing material
bevel by machining, grinding, or arc gouging. If removed by arc gouging, resulting oxidation and
surface roughness shall be removed by grinding.
x A minimum radius of 1.6 mm (1/16”) shall be used at the limit of the cladding removal, unless the
clad material is beveled at least 30º.
x Removal of cladding shall not reduce the thickness of the backing material below the design
thickness.
x The area where cladding has been removed shall be examined by standard copper sulfate
examination, (Blue Vitriol) 5-10% in water, to assure complete removal of the cladding.
The following NDE examinations and production test requirements shall be used on all alloy clad
materials, clad restoration welding and corrosion-resistant weld metal overlay:
x All alloy clad materials, whether roll bonded or explosion bonded, shall be examined in accordance
with ASTM A-578 for both the backing steel and the clad material, at the mill. The acceptance
criteria for the backing steel shall be Level B. The acceptance standard for the clad material shall be
Supplementary Requirement S6, unless otherwise specified.
x After the completion of forming operations (i.e., rolling, pressing, flanging, dishing, etc.) on alloy clad
materials, whether roll bonded or explosion bonded, a10% random examination for lack of bond
shall be performed using the straight beam ultrasonic method. ASTM A-578 shall be the basis for
the examination, excluding the extent of scanning. The acceptance standard for the clad material
shall be Supplementary Requirement S6, unless otherwise specified.
x After the completion of clad restoration welding or weld metal overlay, a chemical analysis to
determine alloy content of the deposited weld metal shall be performed on each shell section and
major component (i.e., heads, tubesheets, etc.), and on each longitudinal and circumferential weld
seam. In addition, all manway attachments and a representative number of nozzles, at least one of
each size, shall also have a chemical analysis performed on them. Production chemical analysis
shall also include a minimum of one test per welding procedure used and one test for each welder or
welding operator employed in production of the component.
x Chemical analysis may be performed using X-ray spectrometer, X-ray emission, X-ray fluorescence,
optical spectroscopy or wet chemical analysis techniques and equipment. Unless otherwise
specified herein or within other applicable specifications or codes, the depth of chemical analysis
shall be no less than the minimum specified overlay thickness.

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x Where 300 Series austenitic stainless steel corrosion-resistant weld metal overlay and clad
restoration welding is specified to meet the chemical composition of equivalent 300 Series austenitic
stainless steel base material, or the minimum requirements of the applicable SFA designation and
AWS Classification of the filler metals, the ferrite content shall be checked with a Severn Gauge,
Ferritiscope, or other magnetic test device traceable to AWS A4.2, Standard Procedure for
Calibrating Magnetic Instruments to Measure the Delta Ferrite Content of Austenitic Steel Weld
Metal. The acceptable range for as-welded ferrite content shall be a ferrite number from 3FN to
12FN, unless the backing material is to be PWHT’d in which case the maximum ferrite content shall
be ferrite number 10FN.
x When ferrite content analysis is required, it shall be performed on each shell section and major
component (i.e., heads, tubesheet, etc.), and on each longitudinal and circumferential weld seam. In
addition, all manway attachments and a representative number of nozzles, at least one of each size,
shall also have a ferrite content analysis performed on them. A ferrite content analysis shall also
include a minimum of one test per welding procedure used and one test for each welder or welding
operator employed in production of the component.
x Standard copper sulfate examination, (Blue Vitriol) 5-10% in water, shall be performed prior to
hydrostatic testing, on all finished surfaces of clad restoration welding and corrosion-resistant weld
metal overlay.
x Liquid penetrant examination shall be performed following the hydrostatic testing, on all finished
surfaces of clad restoration welding and corrosion-resistant weld metal overlay.
Dissimilar Metal Welding

Welds joining pressure-containing parts of two different ferritic steels shall have a weld metal deposit
conforming to the nominal chemical composition of the higher alloy base material unless otherwise
approved by Company.
Welds joining two different ferritic steels, only one of which is a pressure containing part, shall have a
weld metal deposit conforming to the nominal chemical composition of the pressure containing
partbasematerial,unless engineering design specifies otherwise, or approval is obtained from Company.
When joining two different austenitic stainless steels, the filler metal (A No. 8) may match either, unless
a stabilized grade of material is involved, in which case the filler metal shall match the nominal chemical
composition of the stabilized grade of material. The resulting as-welded ferrite content shall be from
3FN to 12FN. Delta ferrite shall be determined from the certified chemical composition analysis of the
filler metal manufacturer and the WRC Delta Ferrite Diagram.
When joining austenitic stainless steels to ferritic steels, the welds shall be made with filler metal as
follows:
x Nickel base alloy filler metal from the SFA 5.11 and SFA 5.14 specifications for design temperatures
exceeding 345ºC (650ºF) or cyclic operating service. Where the process stream contains sulfur at
design temperatures above 400ºF (750ºF), specific written approval must be obtained from
Company to use nickel base alloy filler metal.
x Type 310 filler material is prohibited. (Note: Type 310 filler materials are acceptable only for
welding of Type 310 base materials to themselves).
10.0 ADDITIONAL WELDING REQUIREMENTS FOR STRUCTURAL STEELFABRICATION
All structural steel welding shall be in accordance with the most recent edition of AWS D1.1. AWS
Prequalified or AWS Recommended Welding Procedure Specification formats may be used for structural
steel welding.
Acceptable welding processes for structural steel welding include the following:
x Shielded Metal Arc Welding (SMAW) – Maximum allowable electrode size shall be 5 mm. The
maximum weave width shall be 2½ times the rod diameter.
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x Gas Tungsten Arc Welding (GTAW)

x Gas Metal Arc Welding (GMAW) – Shop welding only using the spray or globular transfer modes
only, completion of groove welds on base materials < 9.5 mm (3/8") total thickness and 9.5 mm
(3/8”) fillet welds on plate and structural steel and any seal welding.
x Flux Cored Arc Welding (FCAW) - Spray transfer mode only. May be self-shielded or auxiliary gas
shielded.
x Submerged Arc Welding (SAW) - Automatic or machine only.
Welding processes other than those listed above require written approval from Company, and shall not
be assumed to be acceptable during proposal stage.
Galvanized structural steel must be ground and cleaned to bright metal prior to welding.
Column and beam splices, full penetration welds for moment connections and groove welds in structural
steel 12.7 mm (1/2”) and over in thickness, shall be nondestructively examined by radiographic or
ultrasonic methods for volumetric weld integrity. Acceptance criteria shall be in accordance with AWS
D1.1.
11.0 ADDITIONAL WELDING REQUIREMENTS FOR PRESSURE VESSELS & HEAT
EXCHANGERS
All welding shall be in accordance with the most recent edition of ASME Section VIII, Division 1 or
Division 2, as applicable.
All Welding Procedure Specifications shall be in accordance with the most recent edition of ASME
Section IX.
Acceptable welding processes for welding of pressure vessels and heat exchangers include the
following:
x Shielded Metal Arc Welding (SMAW)
x Gas Tungsten Arc Welding (GTAW) - Manual, machine, automatic, or orbital.
x Gas Metal Arc Welding (GMAW) - Short circuiting, spray or globular transfer modes. The limitations
of Section 4.0 apply.
x Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary gas shielded only is acceptable
for welding P-1 through P-8 materials.
x Submerged Arc Welding (SAW) - Automatic or machine only.
Welding processes other than those listed above require written approval from Company, and shall not
be assumed to be acceptable during proposal stage.
When poorly fitted joints occur with excessive gap or excessive offset, the supplier shall submit a
separate weld repair procedure indicating with a sketch; the method proposed to bring the joint back to
original design requirements specified in the original Company accepted welding procedure
specification. The supplier shall not assume that backing rings and temporary or permanent backing
strips are acceptable without Company’s review and approval. Any weld joints of this nature found to be
slugged with supplementary filler metal are unacceptable, and shall be removed. Buttering of beveled
ends to close excessive gap is unacceptable without Company review and approval.
Where strength welding of tube-to-tubesheet joints is specified, the supplier shall submit a “mock-up”
sample, suitably sectioned and etched to show full fusion, minimum leak path, and microhardness test
results, to Company for review and approval.
Tube and tubesheet materials for qualification testing shall conform to the actual material type and grade
to be used in production.

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Tube and tubesheet thicknesses for qualification testing shall conform to the actual thicknesses to be
used in fabrication, except that the tubesheet thickness of the mockup need not exceed 2 inches.
The clearance between the outside surface of the tubes and the inside surfaces of the tube holes shall
not exceed clearance used in the Welding Procedure Specification (WPS) qualification tests.
The edges of the tubesheet at the tube holes on the side to be welded shall be free of burrs. The edges
of the tubesheet at the tube holes on the side opposite the weld shall have sharp corners removed.
The welding procedure qualification shall be made in accordance with the rules of ASME Section VIII,
Division 2, Article F-3, Section AF-321. All essential variables and changes requiring requalification are
addressed in Section AF-321.
The procedure qualification shall be made on a test assembly which simulates the conditions to be used
in production with respect to the tube whole pattern and the essential variables listed in AF-321. Unless
specifically noted otherwise herein or within other applicable specifications or codes, the minimum
required number of weld joints shall be three (3).
The test assembly shall be examined by a liquid penetrant method in accordance with ASME Section
VIII, Division 2, Article 9-2.
The assembly shall be sectioned longitudinally through each tube. The thickness of the assembly may
be reduced to ½ inch prior to sectioning. The four (4) faces of each tube exposed by sectioning shall be
polished and etched with a suitable etchant, and shall be visually examined for cracks and verification of
full fusion of weld metal and base metal. The weld throats of all sections, representing the minimum
leakage path, shall not be less than 2/3 of the specified tube wall thickness and shall be free from cracks
on visual examination with 10X magnification.
Traverse microhardness shall be performed on the weld, tube, tubesheet, and tubesheet heat affected
zone. Microhardness results shall be transposed to BrinellHardness equivalent values. Hardness
values shall not exceed the limits for the material, as specified herein or within other applicable
specifications or codes.
When specified herein or within other applicable specifications or codes, Shear Load Tests (Push-outs)
shall be performed on two (2) full size test specimens. This test subjects the specimens to a measured
load sufficient to cause failure. In general, the testing equipment and methods are given in ASTM E8 -
Methods of Tension Testing of Metallic Materials.
All test results, weld samples, and welding procedure specifications shall be submitted for approval.
When strength welding of the tube-to-tubesheet is required herein or within other applicable
specifications or codes, the production weld joints shall be tested after the completion of the first weld
pass, and the second weld pass when specified, by means of an air and soap test. The air pressure
shall be a minimum of 35 kPa (5 psig), and shall be applied from the shell side of the tubesheet. A
bubble forming solution shall be applied to the weld joints to test the integrity of the weld. This test shall
be performed prior to tube rolling. Test procedures shall be in accordance with ASME Section V, Article
10.
Weld overlay of tubesheets shall be liquid penetrant examined prior to hydrostatic testing.
Penning of welds to enhance mechanical properties is prohibited.
12.0 ADDITIONAL WELDING REQUIREMENTS FOR ATMOSPHERIC & LOW PRESSURE
STORAGE TANKS
All welding shall be in accordance with the most recent edition of API-650 and API-620, as applicable.
All Welding Procedure Specifications shall be in accordance with the most recent edition of ASME
Section IX.
Acceptable welding processes for welding atmospheric and low pressure storage tanks include the
following:

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x Shielded Metal Arc Welding (SMAW).

x Gas Tungsten Arc Welding (GTAW).
x Gas Metal Arc Welding (GMAW) - Semi-automatic process, shop fabricated tanks only. Machine or
automatic process shall be used for field fabricated tanks. Root welds that are backgouged and
back-welded may be by short-circuiting transfer mode. All other weldingpasses to be by spray
orglobular transfer modes only. The limitations of Section 4.0 apply.
x Flux Cored Arc Welding (FCAW) - Semi-automatic process, shop fabricated tanks only. Machine or
automatic process shall be used for field fabricated tanks. Spray transfer mode with auxiliary gas
shielding only.
x Submerged Arc Welding (SAW) - Automatic or machine only.
Downhill welding of the wash and cover passes using the SMAW process and low hydrogen electrodes
is subject to written authorization from Company.
The weld seams of sketch plates for tank bottoms and floating roofs shall consist of a minimum of (2)
two weld passes. Single pass weld seams are unacceptable.
13.0 ADDITIONAL WELDING REQUIREMENTS FOR BOILERS, HEATERS & FURNACES
All welding shall be in accordance with the most recent edition of ASME Section I, Section VIII, Division
1, and B31.1, as applicable.
All Welding Procedure Specifications shall be in accordance with the most recent edition of ASME
Section IX.
Acceptable welding processes for welding of boilers, heaters and furnaces include the following:
x Shielded Metal Arc Welding (SMAW).
x Gas Tungsten Arc Welding (GTAW) - Manual, machine, automatic or orbital.
x Gas Metal Arc Welding (GMAW) - Short circuiting, spray or globular transfer modes. The limitations
of Section 4.0 apply.
x Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary shielding for pressure
boundary welding. Spray transfer, self shielded or auxiliary gas shielded, may be used for non-
pressure boundary welding and structural attachment welding.
x Submerged Arc Welding (SAW) - Automatic or machine only.
Welding processes other than those listed above require written approval from Company, and shall not
be assumed as acceptable during proposal stage.
GTAW shall be used on a minimum of the first (2) two weld passes of single-sided groove welds on
ferrous alloy and non-ferrous alloy tubes.
A back-purge with argon shielding gas is required on all low alloy (P-5) and higher alloy material single-
sided groove welds. The purge shall be maintained a minimum of two complete weld passes.
The material used for tube purging dams, and methods employed in their placement, use, and
subsequent removal shall be included in a procedure which specifies the composition and purity of the
gas and the flow rates and time required to obtain adequate purging. This information may be provided
on the Welding Procedure Specification or as a separate procedure, for Company’ review and approval.
14.0 ADDITIONAL WELDING REQUIREMENTS FOR ROTATING EQUIPMENT & AUXILIARY
SUPPORT COMPONENTS
All welding shall be in accordance with the most recent edition of ASME Section VIII, Division 1, B31.3,
or applicable API Code, as applicable.

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All Welding Procedure Specifications shall be in accordance with the most recent edition of ASME
Section IX.
Acceptable welding processes for welding of rotating equipment and auxiliary support components
include the following:
x Shielded Metal Arc Welding (SMAW).
x Gas Tungsten Arc Welding (GTAW) - Manual, machine or automatic.
x Gas Metal Arc Welding (GMAW) - Short circuiting, spray or transfer modes. The limitations of
Section 4.0 apply.
x Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary gas shielding for pressure
boundary welding. Spray transfer, self-shielded or auxiliary gas shielded may be used for non-
pressure boundary welding and structural attachment welding.
x Submerged Arc Welding (SAW) - Automatic or machine only.
Welding processes other than those listed above require written approval from Company, and shall not
be assumed to be acceptable during proposal stage.
Major weld repairs of defects in castings shall have Company’s prior approval. A proposed repair
procedure shall be submitted for Company’s review and approval. The repair procedure shall include as
a minimum:
x A sketch which maps the physical location of the defect(s) within the casting. The major dimensions
of the defect(s) and the severity level associated with them must also be included.
x The NDE method used to detect the existence of the defect(s), and the method planned to assure its
removal and repair.
x The Welding Procedure Specification proposed for the welding repair.
x Any thermal heat treatment procedures required for post-welding applications.
NOTE: A weld repair is considered “major” when it is made to correct leakage on hydrostatic testing, or
when the depth of the cavity prepared for welding exceeds 20% of the actual wall thickness or 1
in., whichever is smaller, or when the extent of the cavity exceeds approximately 10 sq. in.
Welding of structural steel for base components and skid units shall be in accordance with the most
recent edition of AWS D1.1. AWS Prequalified or AWS Recommended Welding Procedure Specification
formats may be used for structural steel welding. The equipment supplier shall receive and approve all
sub-vendor welding procedures for structural steel welding applications. All requirements of Section
11.0 of this specification shall apply for structural steel welding. The supplier shall submit vendor’s Weld
Map along with Welding Procedure Specifications and Procedure Qualification Records to Company for
review and approval.
Welding of lube oil piping and piping components for equipment lubrication systems shall be in
accordance with the most recent edition of ASME B31.3. All Welding Procedure Specifications shall be
in accordance with the most recent edition of ASME Section IX. The equipment supplier shall receive
and approve all sub-vendor welding procedures for lube oil piping applications. All requirements of
Section 16.0 of this specification shall apply for welding of lube oil piping. The supplier shall submit
vendor’s Weld Map along with Welding Procedure Specifications and Procedure Qualification Records to
Company for review and approval.
Welding of ASME code stamped filters and coolers, storage and run-down tanks, and any other
equipment associated with the lubrication system shall be in accordance with the most recent edition of
ASME Section VIII, Division 1. All Welding Procedure Specifications shall be in accordance with the
most recent edition of ASME Section IX. Theequipment supplier shall receive and approve all sub-
vendor welding procedures for equipment associated with lube oil systems. All requirements of Section
12.0 of this specification shall apply for welding of equipment associated with the lube oil system. The

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supplier shall submit vendor’s Weld Map along with Welding Procedure Specifications and Procedure
Qualification Records to Company for review and approval.
Welding of ASME code stamped, or API Plan seal pots and seal oil system shall be in accordance with
the most recent edition of ASME Section VIII, Division 1, or ASME B31.3, as applicable. All Welding
Procedure Specifications shall be in accordance with the most recent edition of ASME Section IX. The
equipment supplier shall receive and approve all sub-vendor welding procedures for seal oil systems.
All requirements of Section 12.0 and Section 16.0 of this specification shall apply for welding of seal oil
systems. The supplier shall submit vendor’s Weld Map along with Welding Procedure Specifications
and Procedure Qualification Records to Company for review and approval.
The supplier shall submit all Welding Procedure Specifications and vendor Weld Maps as part of the
equipment data books.
15.0 ADDITIONAL WELDING REQUIREMENTS FOR FABRICATED PIPING & PIPING
COMPONENTS
All welding shall be in accordance with the most recent edition of ASME B31.1, B31.3, as applicable.
End preparation for groove welds shall be as specified in the welding procedure specification and ASME
B16.25.
All Welding Procedure Specifications shall be in accordance with the most recent edition of ASME
Section IX.
Acceptable welding processes for welding fabricated piping and piping components include the
following:
x Shielded Metal Arc Welding (SMAW).
x Gas Tungsten Arc Welding (GTAW) - Manual, machine or automatic.
x Gas Metal Arc Welding (GMAW) - Short circuiting, spray or globular transfer modes. The limitations
of Section 4.0 apply.
x Flux Cored Arc Welding (FCAW) - Spray transfer mode and auxiliary gas shielded only is acceptable
for welding P-1 through P-8 materials.
x Submerged Arc Welding (SAW) - Automatic or machine only.
Welding processes other than those listed above require written approval from Company, and shall not
be assumed to be acceptable during proposal stage.
Root pass welding of P-1 piping materials may be accomplished using the SMAW, GTAW, or GMAW
welding processes.
Low hydrogen electrodes used with the SMAW processes shall not be used for root passes of single-
sided groove welds, unless backgouging and backwelding can be accomplished.
A back-purge with argon shielding gas is required on all low alloy (P-5) and higher alloy material single-
sided groove welds. The purge shall be maintained a minimum of (2) two complete weld passes.
The GTAW process shall be used on all welding of piping and piping components as follows:
x All low alloy, stainless steel and high alloy single-sided groove weld root and hot passes, as a
minimum.
x All root and hot passes in buttwelds of P-1 materials DN50 (2” NPS) and less.
x All root and hot passes in buttwelds of compressor suction piping.
x All root and hot passes in buttwelds of lube oil and seal oil piping.
x All root and hot passes in buttwelds of piping in processes that involve the conveying of solid
materials.
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The gap on pipe-to-socket fitup for socket welding shall result in a minimum of 1.6 mm (1/16”) after
welding.
Socket welds shall have a minimum of two (2) complete passes, regardless of diameter. For socket
welds on piping diameters of DN50 (2” NPS) and greater, there shall be a minimum of two (2) cap
passes visible.
Branch connections such as weldolets, threadolets, sockolets, and stub-ins shall be joined to the header
by full penetration welds. Incomplete penetration as defined by Table 341.3.2, Note B of ASME B31.3,
is not acceptable.
Branch connections shall be prepared in accordance with Figure 328.4.4 (A), (B) or (C) of ASME B31.3.
A minimum root gap of 1.6 mm (1/16 inches) shall be maintained during welding. The root gap shall be
stated in the welding procedure specification.
The sequence of weldout shall not result in excessive distortion in the piping. Root passes shall be
completed prior to block, or step welding of the remaining weld passes. P-1 material piping distortions
may be corrected using localized flame heating. All low alloy, stainless steel and high alloy material
piping shall not be heated using localized flame heating to correct distortion. Alternative corrective
actions must be proposed to Company, in writing, for approval.
Buttwelds attaching orifice flanges to piping shall have the internal surface of the root passes ground
smooth and flush with the inside diameter of the piping.
When the maintenance of preheat is required for low alloy piping welds (See Section 7.0), it shall be
maintained continuously throughout the welding operation. If preheat is interrupted for any reason, the
weld shall not consist of less than 2/3 the total weld thickness or (2) two complete weld passes,
whichever is greater. All other requirements of Section 7.0 apply.
The entire weld area shall be held at the minimum preheat temperature during the welding operation,
and continuing until the completion of the weldout. Maintaining a minimum interpass temperature
measured at the initiation/termination point of the weld bead shall not be considered maintaining
preheat, except as allowed below. Acceptable methods of preheat application and maintenance are as
follows:
x Flame Heating (By Oxy-Acetylene Torch) - The use of the rosebud heating torch manually applied
and controlled is considered to be an intermittent method of maintaining preheat. Measurement of
preheat temperature is performed after the termination of the welding operation, either when the
welder is changing positions or filler metal, or terminating a weld pass. Provided the interpass
temperature measured does not fall below the minimum specified preheat temperature, reapplication
of heat from the rosebud torch may not be necessary. This method is acceptable for socket welds
andbuttwelds (Max. DN100 (4” NPS) and Wall Thickness Less Than or Equal to 6.4 mm (0.250”)).
x Flame Heating (Propane Ring & Stationary Burners) - The use of propane ring or stationary burners
is considered to be a continuous method of maintaining preheat. Most commonly used in shop
fabrication applications where rolling of the piping component is feasible. This method is acceptable
for any diameter or wall thickness considerations, provided the quantity of burner orifices in the ring,
or the stationary burner size is sufficient to obtain uniform and adequate heating of the metal
surface.
x Resistance Heating Elements - The use of resistance heating elements is considered to be
continuous methods of maintaining preheat. In addition, this method provides a means to perform
slow controlled heating and cooling prior to and after completion of the welding operation. This
temperature control is exceptionally critical as the alloy content increases in the material.
Resistance heating elements are most commonly used in field fabrication applications due to the
quantity of welds that can be preheated at one time (limited only by the size of the controller), and
the fact that the welds that require this preheat also require postweld heat treatment, which can be
accomplished with the same heating element installation, thereby reducing setup and installation
time for postweld heat treatment operations. This method is acceptable for any diameter or wall
thickness considerations.
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Radiography acceptance criteria for all piping welds shall be per the acceptance criteria in ASME B31.3,
Table 341.3.2 for the applicable service condition, i.e. Normal Fluid Service, Severe Cyclic Conditions or
Category D Fluid Service or ASME B31.1, 136.4.5, as applicable.
16.0 WELDING REPAIRS
Routine welding repairs shall be performed using Company approved welding procedures. Company
reserves the right to require detailed written weld repair procedures when deemed necessary by
Company or their Client.
Defective welding shall be completely removed by chipping; grinding, gouging or other Company
approved methods. The excavated area shall be examined by magnetic particle or liquid penetrant test
methods to assure complete removal of the defect(s).
Excavations for repairs performed by arc gouging shall have the same preheat requirements imposed as
the welding procedure used to perform the original welding.
Welding for cosmetic repairs (i.e., undercutting, gouged base metal, etc.) that do not penetrate the full
thickness of the weld or base metal, shall be preheated in accordance with the requirements for full
penetration welding specified in the original Welding Procedure Specification.
Weld undercutting may be repaired by blend grinding provided the base metal is not reduced below the
minimum required thickness.
Welding repairs shall be re-examined by the NDE method originally used to detect the defective welding.
In the event that cracking is found, or there is to be more than one repair attempt on any one defective
area, repairs shall not be performed without Company’s authorization. The vendor shall submit a
welding repair procedure for Company’s review and approval prior to performing welding repairs. The
repair procedure shall contain as a minimum the following information:
x The method for defining the type and extent of defective welding.
x The method for removing the defect.
x The NDE method used for assuring that the defect has been completely removed.
x The Welding Procedure Specification that will be used for the repair welding.
x The NDE method used to re-inspect the weld for acceptability.

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